Optical encoder apparatus for removable connection with printed circuit board and methods of assembling optical encoder

ABSTRACT

There is disclosed optical encoder apparatus for removable connection with a printed circuit board. In an embodiment, the apparatus includes a light emitting component, a light detecting component, a mounting component for attaching the light emitting component thereon, and another mounting component for attaching the light detecting component thereon, wherein each of the mounting components have a removable connection with the printed circuit board. A method of assembling optical encoder apparatus is disclosed. In an embodiment, the method includes attaching a light emitting component and a terminal of a first mounting component to one another; attaching a light detecting component and a terminal of a second mounting component to one another; attaching a terminal of the first mounting component to a printed circuit board; and attaching a terminal of the second mounting component to the printed circuit board. Other embodiments are also disclosed.

This patent application is a divisional application of parent U.S.patent application Ser. No. 11/394,611 filed Mar. 31, 2006 now U.S. Pat.No. 7,439,487 entitled “Optical Encoder Apparatus for RemovableConnection with a Printed Circuit Board and Methods of AssemblingOptical Encoder Apparatus” to Prekumar S. Ramachandran, and claimspriority and other benefits therefrom. The foregoing '611 patentapplication is hereby incorporated by reference herein, in its entirety.

BACKGROUND

Generally, optical encoder apparatus include a single modular componenthaving a light emitting portion and a light detecting portion. Thissingle modular component may be attached to a printed circuit board.However, once the modular component is attached to the printed circuitboard, the resolution of the light detection may not be adjusted.

Furthermore, light may be transmitted directly from the light emittingportion to the light detecting portion of the optical encoder apparatus.This cross-talk can induce error in the optical encoder apparatus.

SUMMARY OF THE INVENTION

In an embodiment, there is provided optical encoder apparatus forremovable connection with a printed circuit board, the apparatuscomprising a light emitting component having an outer surface with aconductive terminal; a light detecting component having an outer surfacewith a conductive terminal; a first mounting component having a surfacefor attaching the outer surface of the light emitting component thereon,a first conductive terminal for electrical connection with theconductive terminal of the light emitting component, and a secondconductive terminal for removable connection with the printed circuitboard; and a second mounting component having a surface for attachingthe outer surface of the light detecting component thereon, a firstconductive terminal for electrical connection with the conductiveterminal of the light detecting component, and a second conductiveterminal for removable connection with the printed circuit board.

In another embodiment, there is provided optical encoder apparatus forremovable connection with a printed circuit board, the apparatuscomprising a light emitting component having an outer surface with aconductive terminal; a light detecting component having an outer surfacewith a conductive terminal; a mounting component having a surface forattaching the outer surface of the light emitting component and theouter surface of the light detecting component thereon, a first set ofconductive terminals for electrical connection with the conductiveterminal of the light emitting component and with the conductiveterminal of the light emitting component, and a second set of conductiveterminals for removable connection with the printed circuit board.

In yet another embodiment, there is provided optical encoder apparatusfor removable connection with a printed circuit board, the apparatuscomprising a light emitting component having an outer surface with aconductive terminal; a light detecting component having an outer surfacewith a conductive terminal; a mounting component having a surface forattaching the outer surface of the light emitting component and theouter surface of the light detecting component thereon, a first set ofconductive terminals for electrical connection with the conductiveterminal of the light emitting component and with the conductiveterminal of the light emitting component, and a second set of conductiveterminals for removable connection with the printed circuit board.

In still another embodiment, there is provided a method of assemblingoptical encoder apparatus, the method comprising attaching a conductiveterminal of a light emitting component and a first conductive terminalof a first mounting component to one another; attaching a conductiveterminal of a light detecting component and a first conductive terminalof a second mounting component to one another; attaching a secondconductive terminal of the first mounting component to a printed circuitboard; and attaching a second conductive terminal of the second mountingcomponent to the printed circuit board.

In another embodiment, there is provided a method of assembling opticalencoder apparatus, the method comprising attaching a conductive terminalof a light emitting component and a first conductive terminal of amounting component to one another; attaching a conductive terminal of alight detecting component and a second conductive terminal of themounting component to one another; and attaching a third conductiveterminal and a fourth conductive terminal of the mounting component to aprinted circuit board, wherein the first conductive terminal and thethird conductive terminal are in electrical connection with one another,and wherein the second conductive terminal and the fourth conductiveterminal are in electrical connection with one another.

Other embodiments are also disclosed.

BRIEF DESCRIPTION OF THE DRAWINGS

Illustrative embodiments of the invention are illustrated in thedrawings, in which:

FIG. 1 illustrates an embodiment of an optical encoder apparatus havinga light detecting component configured for removable connection with aprinted circuit board;

FIG. 2 illustrates a light emitting component of the apparatus shown inFIG. 1;

FIG. 3 illustrates a light detecting component of the apparatus shown inFIG. 1;

FIG. 4 illustrates a first mounting component of the apparatus shown inFIG. 1;

FIG. 5 illustrates a second mounting component of the apparatus shown inFIG. 1;

FIG. 6 illustrates a replacement light detecting component of theapparatus shown in FIG. 1;

FIG. 7 illustrates a replacement mounting component of the apparatusshown in FIG. 1;

FIG. 8 illustrates an optical encoder apparatus mounted on a printedcircuit board with a gap between the light emitting component and thelight detecting component;

FIG. 9 illustrates one embodiment of an optical encoder apparatus havinga light detecting component configured for removable connection with aprinted circuit board;

FIG. 10 illustrates a light detecting component of the apparatus shownin FIG. 9;

FIG. 11 illustrates a mounting component of the apparatus shown in FIG.9;

FIG. 12 illustrates an embodiment of a printed circuit board configuredto position the light detecting component of FIG. 10 adjacent to thelight emitting device;

FIG. 13 illustrates another embodiment of a printed circuit boardconfigured to position the light detecting component of FIG. 10 with agap between the light emitting device;

FIG. 14 illustrates the placement of the light detecting component ofFIG. 10 on the printed circuit board of FIG. 13 with a gap between thelight emitting device and the light detecting component;

FIG. 15 illustrates one embodiment of an optical encoder apparatushaving a light detecting component configured for removable connectionwith a printed circuit board;

FIG. 16 illustrates a light emitting component of the apparatus shown inFIG. 15;

FIG. 17 illustrates a light detecting component of the apparatus shownin FIG. 15;

FIG. 18 illustrates a mounting component of the apparatus shown in FIG.15; and

FIGS. 19-22 are flow chart diagrams for various methods of assemblingoptical encoder apparatus.

DETAILED DESCRIPTION OF AN EMBODIMENT

In an embodiment, the optical encoder apparatus may allow adjustment ofthe level of resolution without changing the main printed circuit board.

In one embodiment, the optical encoder apparatus may have increasedperformance as the LED and detector may be assembled together fromseparate components, and a blocking portion may be provided to preventcrosstalk between the LED and detector.

Referring to FIG. 1, there is shown an optical encoder apparatus 100 forremovable connection with a printed circuit board 102. In an embodiment,apparatus 100 may include a light emitting component 104, a lightdetecting component 106, a first mounting component 108, and a secondmounting component 110.

Looking at FIG. 2, there is shown light emitting component 104 having anouter surface 112 with a conductive terminal 114.

Looking at FIG. 3, there is shown light detecting component 106 havingan outer surface 116 with a pair of conductive terminals 118. In anotherembodiment, light detecting component 106 may have a single conductiveterminal 118 or multiple conductive terminals 118.

Looking at FIG. 4, there is shown first mounting component 108 having asurface 120 for attaching outer surface 112 of light emitting component104 (FIG. 2) thereon. In an embodiment, first mounting component 108 mayinclude a first conductive terminal 122 and a second conductive terminal124. First conductive terminal 122 may be configured for electricalconnection with conductive terminal 114 of light emitting component 124(FIG. 2). Second conductive terminal 104 may be configured for removableconnection with printed circuit board 102 (FIG. 1).

Looking at FIG. 5, there is shown second mounting component 110 having asurface 126 for attaching outer surface 116 of the light detectingcomponent 106 (FIG. 3) thereon. In an embodiment, second mountingcomponent 110 may include a first pair of conductive terminal 128 and asecond conductive terminal 130. First pair of conductive terminals 128may be configured for electrical connection with the pair of conductiveterminals 118 of light detecting component 106. In an alternativeembodiment, a single conductive terminal 128 or multiple conductiveterminals 128 may be provided. Second conductive terminal 130 may beconfigured for removable connection with printed circuit board 102.

Referring now to FIGS. 1 and 2, and in an embodiment, light emittingcomponent 104 may include a light emitting diode 132. Outer surface 112of light emitting component 104 may be a modular component containinglight emitting diode 132.

Referring now to FIGS. 1 and 3, and in an embodiment, light detectingcomponent 106 may include a detector 134, which may include, but is notlimited to, a photodiode 134. Outer surface 116 of light detectingcomponent may be a modular component containing photodiode 134.

Looking at FIG. 1, there is shown light emitting component 106 withlight emitting diode 132, outer surface 112 of the light emittingcomponent 104 is a modular component containing light emitting diode132, the light detecting component 106 with photodiode 134, and whereinouter surface 116 of light detecting component 106 is a modularcomponent containing photodiode 134.

Referring still to FIGS. 1-5, there is shown optical encoder apparatus100 (FIG. 1) having first mounting component 108 (FIGS. 1 and 4) andsecond mounting component 110 (FIGS. 1 and 5) as separate modularcomponents from light emitting component 104 (FIGS. 1 and 2) and lightdetecting component 106 (FIGS. 1 and 3), respectively.

Looking again at FIG. 4, and in one embodiment, surface 120 of firstmounting component 108, which is configured for attaching light emittingcomponent 104 thereon, may include a solder material 136.

Looking again at FIG. 5, and in one embodiment, surface 126 of secondmounting component 110, which is configured for attaching lightdetecting component 106 thereon, may include a solder material 138.

Referring to FIG. 2, and in an embodiment, outer surface 112 of lightemitting component 104 may include a solder material 140.

Referring to FIG. 3, and in an embodiment, outer surface 116 of lightdetecting component 106 may include a solder material 142.

Looking at FIGS. 1, 2 and 4, and in one embodiment, surface 120 of firstmounting component 108, which may be configured for attaching the lightemitting component 104 thereon, may include solder material 136. Outersurface 112 of light emitting component may also include solder material140. Solder material 136 of first mounting component 108 and soldermaterial 140 of light emitting component may attach first mountingcomponent 108 and light emitting component 104 to one another.

Looking still at FIGS. 1, 3 and 5, and in one embodiment, surface 126 ofsecond mounting component 110, which may be configured for attachinglight detecting component 106 thereon, may include solder material 138.Outer surface 116 of light detecting component 106 may include soldermaterial 142. Solder material 138 of second mounting component 110 andsolder material 142 of light detecting component 106 may attach secondcomponent 110 and light detecting component 106 to one another.

Referring to FIGS. 1, 4 and 5, and in an embodiment, second conductiveterminal 124 of first mounting component 108 may include a jack 144.Printed circuit board 102 may form a first through hole 146. Jack 144 offirst mounting component 108 and first through hole 146 may be sized forremovable connection with one another. Second conductive terminal 124 ofthe first mounting component 108 may include a pair of jacks 148.Printed circuit board 102 may form a pair of second through holes 150.Jack 148 of second mounting component 110 and second through hole 150may be sized for removable connection with one another.

Referring to FIGS. 6 and 7, and in an embodiment, there is shown areplacement light detecting component 106A (FIG. 6) and a replacementmounting component 110A (FIG. 7). Looking at FIG. 6, replacement lightdetecting component 106A has an outer surface 116A with a pair ofconductive terminals 118A.

Looking at FIGS. 1, 6 and 7, a replacement mounting component 110A (FIG.7) may be provided for attaching replacement light detecting component106A (FIG. 6) to printed circuit board 102 (FIG. 1) at the location oflight detecting component 106 and second mounting component 110.Replacement mounting component 110A (FIG. 7) may have a surface 126A forattaching outer surface 116A of light detecting component 106A thereon.In an embodiment, replacement mounting component 110A may include a pairof first conductive terminals 128A and a pair of second conductiveterminals 130A. First conductive terminals 128A may be configured forelectrical connection with the conductive terminals 118A of replacementlight detecting component 106A. Second conductive terminals 130A may beconfigured for removable connection with printed circuit board 102.

Light detecting component 106 may have a given resolution. Replacementlight detecting component 106A may have a given resolution. In oneembodiment, the given resolution of light detecting component 106 andthe given resolution of replacement light detecting component 106A aredifferent from one another. In another embodiment, the given resolutionof light detecting component 106 and replacement light detectingcomponent 106A are equal to one another.

Light detecting component 106 and replacement light detecting component106A may each have a given resolution chosen from, for example, but notlimited to, a value selected 75 LPI, 150 LPI, and 180 LPI.

Referring to FIG. 1, and in an embodiment, second terminal 124 of firstmounting component 106 and second conductive terminal 130 of secondmounting component 110 each form a removable connection to printedcircuit board 102 at locations adjacent to one another. The locations ofthe removable connection of first mounting component 108 and theremovable connection of second mounting component 110 are disposed onprinted circuit board 102 to position outer surface 112 of the lightemitting component 104 and outer surface 116 of light detectingcomponent 106 in contact with one another.

Looking at FIG. 8, and in an embodiment, the locations of the removableconnection of first mounting component 108 and the removable connectionof second mounting component 110 are disposed on printed circuit board102 to position outer surface 112 of light emitting component 104 andouter surface 116 of light detecting component 106 separate from oneanother. For example, to position light emitting component 104 and lightdetecting component 116 with respect to one another, one or more of theposition of through holes 146 and through holes 150, and the position ofterminal 124 and terminal 130 may be adjusted.

Looking at FIGS. 1 and 8, and in one embodiment, there is shown anopaque region 152 on at least one of outer surface 112 of light emittingcomponent 104 and outer surface 116 of light detecting component 106.Opaque region 152 is configured to limit direct light transfer fromlight emitting component 104 to light detecting component 106.

In one embodiment, opaque region 152 may include a roughed up portion oflight emitting component 104. Opaque region 152 may include a roughed upportion of light detecting component 106. In another embodiment, opaqueregion 152 may include a material applied to light emitting component104. Opaque region 152 may include a material applied to light detectingcomponent 106.

Looking at FIG. 2, light emitting component 104 may have a domed region154 to emit light. In one embodiment, a projection 156 may extend fromlight emitting component 104 to provide scratch protection to domedregion 154.

Looking at FIG. 3 light detecting component 106 may have a domed region158 to receive light. In an embodiment, a projection 160 may extend fromlight detecting component 106 to provide scratch protection to domedregion 158.

Referring now to FIG. 91 and in an embodiment, there is provided opticalencoder apparatus 900 for removable connection with a printed circuitboard 902. In an embodiment, apparatus 900 may include a light detectingcomponent 904, a mounting component 906, and a light emitting device908.

Looking at FIG. 10, there is shown light detecting component 904 havingan outer surface 910 with a pair of conductive terminals 912.

Looking at FIG. 11, there is shown mounting component 906 having asurface 914 for attaching outer surface 910 of light detecting component904 thereon. In an embodiment, mounting component 906 may include afirst conductive terminal 916 and a second conductive terminal 918.First pair of conductive terminals 916 may be configured for electricalconnection with conductive terminal 912 of light detecting component904. Second conductive terminal 918 may be configured for removableconnection with printed circuit board 902.

Light emitting device 908 may be in connection with printed circuitboard 902 at a given location. In an embodiment, removable connection918 of mounting component 906 is removably attached to printed circuitboard 902 adjacent to the given location of light emitting device 908.

In one embodiment, second conductive terminal 918 of mounting component906 may include a jack 918. Printed circuit board 902 may form a pair ofthrough holes 920. Jack 918 and through hole 920 may be sized forremovable connection with one another.

Referring to FIG. 12, and in an embodiment, light emitting device 908and through hole 920 are located a given distance 1200 from one another.Given distance 1200 may position light detecting component 904 incontact with light emitting device 908 at location 922 (FIG. 9) whenmounting component 906 is attached to printed circuit board 902.

Looking at FIGS. 13 and 14, and in one embodiment, light emitting deviceand through hole are located a given distance 1300 from one another(FIG. 13). Given distance 1300 may position light detecting componentand light emitting device with a gap 1400 therebetween (FIG. 14) whenmounting component 906 is attached to printed circuit board 902.

Referring to FIG. 15, and in an embodiment, there is shown an opticalencoder apparatus 1500 for removable connection with a printed circuitboard 1502. In an embodiment, apparatus 1500 may include a lightemitting component 1504, a light detecting component 1506, and amounting component 1508.

Looking at FIG. 16, and in an embodiment, light emitting component 1504may include an outer surface 1510 with a conductive terminal 1512.

Looking at FIG. 17, and in one embodiment, light detecting component1506 may include an outer surface 1514 with a pair of conductiveterminals 1516.

Looking at FIG. 18, and in an embodiment, mounting component 1508 mayinclude a surface 1518 for attaching outer surface 1510 of lightemitting component 1504 and outer surface 1514 of light detectingcomponent 1506 thereon. Mounting component 1508 may include a first setof conductive terminals 1520 and a second set of conductive terminals1522. First set of conductive terminals 1520 may be configured forelectrical connection with conductive terminal 1512 of light emittingcomponent 1504 and with conductive terminal 1516 of light emittingcomponent 1504. Second set of conductive terminals 1522 may beconfigured for removable connection with printed circuit board 1502.

Looking at FIG. 19, there is shown optical encoder apparatus 1900 forremovable connection with a printed circuit board 1902. In anembodiment, apparatus 1900 may include a light emitting component 1904,a light detecting component 1906, and a mounting component 1908.

Referring to FIG. 19, and in an embodiment, there is shown a method 1900of assembling optical encoder apparatus. Method 1900 may includeattaching 1902 a conductive terminal of a light emitting component and afirst conductive terminal of a first mounting component to one another.Method 1900 may include attaching 1904 a conductive terminal of a lightdetecting component and a first conductive terminal of a second mountingcomponent to one another. Method 1900 may include attaching 1906 asecond conductive terminal of the first mounting component to a printedcircuit board. Method 1900 may include attaching 1908 a secondconductive terminal of the second mounting component to the printedcircuit board.

Referring to FIG. 20, and in an embodiment, there is shown a method 2000of assembling optical encoder apparatus. Method 2000 may includeattaching 2002 a conductive terminal of a light emitting component and afirst conductive terminal of a first mounting component to one another.Method 2000 may include attaching 2004 a conductive terminal of a lightdetecting component and a first conductive terminal of a second mountingcomponent to one another. Method 2000 may include attaching 2006 asecond conductive terminal of the first mounting component to a printedcircuit board. Method 2000 may include attaching 2008 a secondconductive terminal of the second mounting component to the printedcircuit board. Method 2000 may include detaching 2010 the secondconductive terminal of the second mounting component from the circuitboard. Method 2000 may include attaching 2012 a conductive terminal of areplacement light detecting component to a replacement mountingcomponent. Method 2000 may include attaching 2014 a second conductiveterminal of the replacement mounting component to the printed circuitboard.

In an embodiment, method 2000 may include selecting the light detectingcomponent and replacement light detecting component to have differentresolutions from one another.

Referring to FIG. 21, there is shown a method 2100 of assembling opticalencoder apparatus. In an embodiment, method 2100 may include attaching2102 a conductive terminal of a light emitting component and a firstconductive terminal of a mounting component to one another. Method 2100may include attaching 2104 a conductive terminal of a light detectingcomponent and a second conductive terminal of the mounting component toone another. Method 2100 may include attaching 2106 a third conductiveterminal and a fourth conductive terminal of the mounting component to aprinted circuit board, wherein the first conductive terminal and thethird conductive terminal are in electrical connection with one another,and wherein the second conductive terminal and the fourth conductiveterminal are in electrical connection with one another.

Referring to FIG. 22, there is shown a method 2200 of assembling opticalencoder apparatus. In an embodiment, method 2200 may include attaching2202 a conductive terminal of a light emitting component and a firstconductive terminal of a mounting component to one another. Method 2200may include attaching 2204 a conductive terminal of a light detectingcomponent and a second conductive terminal of the mounting component toone another. Method 2200 may include attaching 2206 a third conductiveterminal and a fourth conductive terminal of the mounting component to aprinted circuit board, wherein the first conductive terminal and thethird conductive terminal are in electrical connection with one another,and wherein the second conductive terminal and the fourth conductiveterminal are in electrical connection with one another. Method 2200 mayinclude detaching 2208 the third conductive terminal and a fourthconductive terminal of the mounting component from the printed circuitboard. Method 2200 may include attaching 2210 a conductive terminal of areplacement light emitting component and a first conductive terminal ofa replacement mounting component to one another. Method 2200 may includeattaching 2212 a conductive terminal of a replacement light detectingcomponent and a second conductive terminal of the replacement mountingcomponent to one another. Method 2200 may include attaching 2214 a thirdconductive terminal and a fourth conductive terminal of the replacementmounting component to a printed circuit board, wherein the firstconductive terminal and the third conductive terminal are in electricalconnection with one another, and wherein the second conductive terminaland the fourth conductive terminal are in electrical connection with oneanother.

1. Optical encoder apparatus for removable connection with a printedcircuit board, the apparatus comprising: a light detecting componenthaving an outer surface with a conductive terminal; a mounting componenthaving a surface for attaching the outer surface of the light detectingcomponent thereon, a first conductive terminal for electrical connectionwith the conductive terminal of the light detecting component, and asecond conductive terminal for removable connection with the printedcircuit board; and a light emitting device in connection with theprinted circuit board at a given location, wherein the removableconnection of the mounting component is removably attached to theprinted circuit board adjacent to the given location of the lightemitting device.
 2. Apparatus in accordance with claim 1, wherein thesecond conductive terminal of the mounting component comprises a jack,the printed circuit board forms a through hole, and the jack and thethrough hole are sized for removable connection with one another. 3.Apparatus in accordance with claim 1, wherein the light emitting deviceand the through hole are located a given distance from one another so asto position the light detecting component in contact with the lightemitting device when the mounting component is attached to the printedcircuit board.
 4. Apparatus in accordance with claim 3, wherein thelight emitting device and the through hole are located a given distancefrom one another so as to position the light detecting component and thelight emitting device with a gap therebetween when the mountingcomponent is attached to the printed circuit board.